Vehicle Door Secondary Sealing System

ABSTRACT

A seal for use with a vehicle door is provided, the seal preferably used as a secondary or tertiary seal to provide additional passenger cabin sound isolation and weather proofing. The seal is attached to a seam within the door jamb, the seal formed by coupling a central body panel flange to a rear quarter panel flange.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims benefit of the filing date of U.S. Provisional Patent Application Ser. No. 61/424,900, filed 20 Dec. 2010, the disclosure of which is incorporated herein by reference for any and all purposes.

FIELD OF THE INVENTION

The present invention relates generally to vehicle structures and, more particularly, to a secondary seal for use with a vehicle door.

BACKGROUND OF THE INVENTION

A conventional vehicle uses a variety of structures and seals to acoustically isolate the passenger cabin from vehicle generated noise (e.g., motor and/or engine noise, fan noise, etc.) as well as road and wind noise and other externally generated sounds. Exemplary sound isolation systems include sound deadening panels, interior treatments and specialized component mounting systems. Additionally, sound seals are used throughout the vehicle, especially at those locations where it is difficult to employ other sound isolation systems such as at the juncture of the doors and windows with the body. As the primary purpose of such seals is for weatherproofing, door and window seals are typically referred to as weather seals or strips.

In general, a vehicle door includes a primary weather seal that is mounted along the peripheral portion of the door, or on the adjoining face of the door jam. Such seals, which are typically U- or D-shaped, are positioned such that when the door is closed the seal is compressed. A vehicle often includes a secondary seal that is mounted to the flange created by the juncture of the body side panel and the vehicle's structural components (e.g., rockers, pillars, roof structure, etc.). The secondary seal provides further sound isolation as well as cosmetically covering the juncture of the body/frame components.

While it is known to include a variety of seals around the periphery of a door, it is desirable that the quality and location of these seals be improved in order to achieve increased sound isolation. The present invention provides an additional door seal that provides increased acoustic isolation of the vehicle passenger cabin.

SUMMARY OF THE INVENTION

The present invention provides a seal for use with a vehicle door, where the seal is preferably used as a secondary or tertiary seal to provide additional passenger cabin sound isolation and weather proofing. The seal is attached to a seam within the door jamb, the seal formed by coupling a central body panel flange to a rear quarter panel flange.

In accordance with the invention, a vehicle door sealing system is provided that is comprised of a central body panel attached to an underlying vehicle frame, where the central body panel includes a contoured region that extends away from the passenger cabin door opening; a rear quarter panel attached to the underlying vehicle frame; a flange seam formed by coupling (for example by rivets and/or welds) a central body panel flange to a complementary rear quarter panel flange, where the flange seam is separate from and outwardly displaced from the central body panel seam formed by coupling the central body panel to the underlying vehicle frame; and a seal attached to and covering at least a portion of the flange seam, where the seal is fabricated from a resilient, elastomeric material (e.g., natural elastomers, synthetic elastomers) and is compressed when the vehicle passenger cabin door is closed. The seal may include a groove configured to fit over the flange seam. The seal may include a groove configured to fit over the flange seam and which includes a plurality of protrusions configured to secure the seal to the flange seam. The seal may include a cavity extending longitudinally through the seal, where the cavity is compressed when the vehicle door is closed. The seal may be bonded to the flange seam.

A further understanding of the nature and advantages of the present invention may be realized by reference to the remaining portions of the specification and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 provides an outside view of the side and rear quarter body panels of an exemplary vehicle utilizing the present invention;

FIG. 2 provides a perspective, detailed view of the contoured region of the vehicle body panel that resides between the rear vehicle door opening and the rear quarter panel;

FIG. 3 provides a similar view to that shown in FIG. 2, with the addition of a secondary seal;

FIG. 4 provides a cross-sectional view of a preferred secondary seal for use with the invention; and

FIG. 5 provides a detailed view of the secondary seal in place over the seam formed by joining the complementary flanges of the body and rear quarter panels.

DESCRIPTION OF THE SPECIFIC EMBODIMENTS

FIG. 1 is a side view of the central portion of the body structure of a vehicle 100. This view shows the central body panel 101 as well as the rear quarter panel 103. Also visible are a plurality of the body panel connections 105 to the underlying vehicle frame, e.g., rocker panel, B-pillar, roof support structure, etc. The body panel connections are comprised of welds and/or rivets.

In accordance with the invention, central body panel 101 is shaped to provide a continuous, non-seamed, contoured region 107 that extends the region between the door jamb and the door (not shown). Contoured region 107 includes a flange that is mechanically joined, for example via a plurality of spot welds or rivets, to a complementary flange of rear quarter panel 103. Thus, as shown, the seam formed by the junction of the rear quarter panel 103 to the body panel 101 is separate and outwardly displaced from the seam 109 formed by the junction of the body panel 101 to the underlying vehicle frame. Outwardly displacing the rear quarter panel seam within the door jamb provides an additional location for a seal 111. As described below, seal 111 is configured to cover, and attach to, the junction of the two body panels, i.e., central panel 101 and rear quarter panel 103.

FIG. 2 provides a detailed view of the joint (i.e., seam) 201 formed by coupling the complimentary flanges of rear quarter panel 103 to that of body panel 101, and more specifically to the flange formed on region 107 of body panel 101. This view shows a plurality of welds or rivets 203 used to couple the two panels together.

FIG. 3 provides a similar view to that provided in FIG. 2, although in this view the welds/rivets are hidden and underlying rocker panel 301 is visible. Also visible in FIG. 3 is secondary seal 111. In this view only a portion of seal 111 is visible, thus clarifying its placement. In the preferred embodiment, seal 111 extends along substantially the entire seam 201 that falls within the door jamb as shown in FIG. 1, i.e., between approximately upper juncture point 303 to lower juncture point 305. When the rear vehicle door closes, seal 111 is compressed. Preferably seal 111 is held in place using an interference fit to seam 201 as described below. Alternately, or in addition to an interference fit, seal 111 may be bonded to seam 201.

FIG. 4 provides a cross-sectional view of secondary seal 111 while FIG. 5 provides a detailed view of seal 111 mounted to flange joint 201. Seal 111 may be made of any of a variety of resilient, elastomeric materials, both natural (e.g., rubber) and synthetic (e.g., inorganic and organic polymers), selected to retain its resiliency and elasticity over a wide temperature range while resisting degradation from normal environmental conditions (UV exposure, rain and humidity, common airborne environmental chemicals, etc.) over the expected life of the vehicle. Preferably seal 111 is formed as a single piece seal as shown.

Seal 111 includes a channel 401 sized to fit flange joint 201. Although channel 401 may be bonded to flange joint 201, preferably channel 401 includes multiple inwardly directed elastic protrusions 403. Protrusions 403 may be formed as extended ‘fingers’ as shown, or simply as bumps. The use of shaped and angled protrusions 403 as illustrated in FIG. 4 eases application of seal 111 to seam 201, while helping to secure the seal and prevent its inadvertent removal. It will be appreciated that fewer or greater numbers of seal retention protrusions 403 may be used, and that the protrusions may be used alone or in combination with an adhesive.

Preferably seal 111 is shaped so that when it is properly positioned over joint 201, a first sealing surface 405 rests firmly against the surface of contoured face 107 and a second sealing surface 407 rests firmly against the face of rear quarter panel 103 as shown in FIG. 5. Sealing surfaces 405 and 407 help to prevent contaminants from lodging under the edges of the seal, potentially compromising the seal.

Preferably seal 111 includes a cavity, or lumen, 409 that extends at least partially, and in some embodiments completely, through the length of the seal. Cavity 409 increases the compressibility and deformability of seal 111 and, to some extent, the surface area of the seal that contacts the door when the door is closed, both of which help to achieve superior noise and environmental sealing characteristics.

It should be understood that identical element symbols used on multiple figures refer to the same component, or components of equal functionality. Additionally, the accompanying figures are only meant to illustrate, not limit, the scope of the invention and should not be considered to be to scale.

Systems and methods have been described in general terms as an aid to understanding details of the invention. In some instances, well-known structures, materials, and/or operations have not been specifically shown or described in detail to avoid obscuring aspects of the invention. In other instances, specific details have been given in order to provide a thorough understanding of the invention. One skilled in the relevant art will recognize that the invention may be embodied in other specific forms, for example to adapt to a particular system or apparatus or situation or material or component, without departing from the spirit or essential characteristics thereof. Therefore the disclosures and descriptions herein are intended to be illustrative, but not limiting, of the scope of the invention which is set forth in the following claims. 

1. A vehicle door sealing system comprising: a single piece central body panel attached to a first portion of an underlying vehicle frame, wherein said single piece central body panel includes a contoured region that extends away from a vehicle passenger cabin door opening, said contoured region of said single piece central body panel further comprising a first panel flange; a rear quarter panel attached to a second portion of said underlying vehicle frame, said rear quarter panel further comprising a second panel flange, wherein said second panel flange is complementary to said first panel flange; a flange seam formed by coupling said first panel flange to said second panel flange, wherein said flange seam is separate from and outwardly displaced from a central body panel seam formed by coupling said single piece central body panel to said first portion of said underlying vehicle frame, and wherein said flange seam is within a door jamb corresponding to said vehicle passenger cabin door opening; and a seal attached to and covering at least a portion of said flange seam, wherein said seal is fabricated from a resilient, elastomeric material, and wherein said seal is compressed when a vehicle door corresponding to said vehicle passenger cabin door opening is in a closed position.
 2. The vehicle door sealing system of claim 1, said seal further comprising a groove configured to fit over said flange seam when said seal is attached to said portion of said flange seam.
 3. The vehicle door sealing system of claim 2, said seal further comprising a plurality of protrusions within said groove configured to secure said seal to said flange seam when said seal is attached to said portion of said flange seam.
 4. The vehicle door sealing system of claim 1, said seal further comprising a cavity extending longitudinally through said seal, wherein said cavity is compressed when said vehicle door corresponding to said vehicle passenger cabin door opening is in said closed position.
 5. The vehicle door sealing system of claim 1, wherein said seal is fabricated from a natural elastomer.
 6. The vehicle door sealing system of claim 1, wherein said seal is fabricated from a synthetic elastomer.
 7. The vehicle door sealing system of claim 1, wherein said first panel flange is coupled to said second panel flange by a plurality of rivets.
 8. The vehicle door sealing system of claim 1, wherein said first panel flange is coupled to said second panel flange by a plurality of welds.
 9. The vehicle door sealing system of claim 1, wherein said seal is bonded to said flange seam. 